Vibrationally isolated support construction for an air handling unit

ABSTRACT

A support system for an air handling unit (AHU) including a first rail supporting the AHU and a second rail supporting the first rail. A vibration isolator is disposed between the first rail and the second rail to vibrationally isolate the AHU from the second rail. The vibration isolator includes a spring secured between opposed spring retainers. An adjusting member threadedly receives the upper spring retainer. The first rail structurally carries the guide member along at least two positions. An angle is secured to the second rail, and the second end of the structural member slidably engages the guide member. Rotating the adjusting member with respect to the spring retainer in one direction compresses the spring between the spring retainers to support the weight of the first rail and the AHU. The angle constrains the AHU to movement along the guide member.

CROSS REFERENCE TO RELATED APPLICATIONS

This Application claims the benefit of U.S. Provisional Application No.60/495,042, filed Aug. 14, 2003, and is related to application Ser. No.10/916.895, filed contemporaneously with this Application on Aug. 12,2004, entitled “RACEWAY CONSTRUCTION FOR AN AIR HANDLING UNIT” assignedto the assignee of the present invention and which is incorporatedherein by reference, to application Ser. No. 10/916,890, filedcontemporaneously with this Application on Aug. 12, 2004, entitled“CORNER CAP MEMBER CONSTRUCTION FOR AN AIR HANDLING UNIT” assigned tothe assignee of the present invention and which is incorporated hereinby reference, to application Ser. No. 10/916,894, filedcontemporaneously with this Application on Aug. 12, 2004, entitled“CORNER ASSEMBLY CONSTRUCTION FOR AN AIR HANDLING UNIT” assigned to theassignee of the present invention and which is incorporated herein byreference, to application Ser. No. 10/917,226, filed contemporaneouslywith this Application on Aug. 12, 2004, entitled “PANEL CONSTRUCTION FORAN AIR HANDLING UNIT” assigned to the assignee of the present inventionand which is incorporated herein by reference, to application Ser. No.10/917,215, filed contemporaneously with this Application on Aug. 12,2004, entitled “ROOF PANEL CONSTRUCTION FOR AN AIR HANDLING UNIT”assigned to the assignee of the present invention and which isincorporated herein by reference, and to application Ser. No.10/916,852, filed contemporaneously with this Application on Aug. 12,2004, entitled “MOTOR BELT TENSIONING CONSTRUCTION FOR AN AIR HANDLINGUNIT” assigned to the assignee of the present invention and which isincorporated herein by reference.

FIELD OF THE INVENTION

The present invention is directed to an air handling unit construction,and more particularly, is directed to a support construction thatisolates vibrations associated with operating the air handling unit.

BACKGROUND OF THE INVENTION

Air Handling Units (AHUs) are one of several components in cooling andheating systems. They are an important component as the AHU houses anumber of components used in the system to provide forced air forclimate control in a particular structure. AHU components typicallyinclude motors, heating/cooling coils, and blowers as well as therequired interface connections to effect such climate control.

The AHU is an enclosed interconnected framed panel structure. The framedpanel structures have insulated panels that are supported betweenframing members, also referred to as raceways, to define interconnectedrectangular compartments. AHUs are typically large and bulky, the amountof floor space required to accommodate the AHU being commonly referredto as a “footprint.” Due to the layout of a particular structure, theAHU may be located in any number of locations, including rooftopinstallations.

To reduce the footprint, the AHU compartments are mounted atop eachother. Since the compartment containing the blower assembly and motor isoften mounted atop other AHU structures, vibration isolation is highlydesirable. That is, by virtue of the operation of the motor and blowerassembly, vibrations may be produced that could otherwise propagate toadjacent AHU structures and possibly to ductwork, generating noise orpossibly causing damage to components subjected to these vibrations.

One attempted solution to this concern, U.S. Pat. No. 5,396,782, isdirected to an integral suspension system for an air conditioning systemadapted for mounting the air conditioning system to a support surface.Substantially enclosed spring support receptacles are formed at each endof Z rails for securing springs therein. A set of four retaining boltsis arranged within the spring support receptacles for contacting theouter periphery of the base coil of the spring when mounted within thereceptacle to prevent lateral movement of the spring. The springscollectively support the Z rails which likewise support cross channelsfor mounting AHU components. However, this suspension systemconstruction requires specially configured structural components thatmay add significantly to the cost of the AHU.

What is needed is an air handling unit construction provided with avibration isolation device having a minimum number of components and nospecially machined structural parts to minimize costs associated withfabrication and installation.

SUMMARY OF THE INVENTION

The present invention relates to a support system for an air handlingunit including a first frame member, the first frame member supportingthe air handling unit. A second frame member, the second frame membersupports the first frame member. A vibration isolator disposed betweenthe first frame member and the second frame member, the vibrationisolator to substantially vibrationally isolate the air handling unitfrom the second frame member. The vibration isolator includes aresilient device having opposed ends. A first retainer abuts the secondframe member, the first retainer configured to receive one end of theresilient device. A second retainer, the second retainer is configuredto receive the other end of the resilient device. An adjusting member isthreadedly received by the second retainer along a first axis, theadjusting member having a first end adjacent the first frame member. Aguide member, the guide member is structurally carried by the firstframe member along a second axis by at least two positions, the secondaxis being substantially parallel to the first axis and not coaxial withthe first axis. A structural member has a first end and a second end,the first end of the structural member secured to the second framemember and the second end of the structural member slidably engaging theguide member between the at least two positions of the first framemember. Sufficiently rotating the adjusting member about the first axiswith respect to the second retainer to actuate the head in a directionaway from the second retainer, the resilient device is compressedbetween the first retainer and the second retainer, the first end of theadjusting member abutting the first frame member to support the weightof the first frame member and the air handling unit. The second end ofthe structural member substantially constrains movement of the airhandling unit along the second axis between the at least two positionsof the first frame member.

The present invention further relates to a support system for airhandling unit having a first compartment supported atop a secondcompartment including a first frame member, the first frame membersupporting the first air handling unit compartment. A second framemember, the second frame member supports the first frame member, thesecond frame member disposed atop the first compartment. A vibrationisolator is disposed between the first frame member and the second framemember, the vibration isolator to substantially vibrationally isolatethe air handling unit from the second frame member. The vibrationisolator includes a resilient device having opposed ends. A firstretainer abuts the second frame member, the first retainer configured toreceive one end of the resilient device. A second retainer, the secondretainer is configured to receive the other end of the resilient device.An adjusting member is threadedly received by the second retainer alonga first axis, the adjusting member having a first end adjacent the firstframe member. A guide member, the guide member is structurally carriedby the first frame member along a second axis by at least two positions,the second axis being substantially parallel to the first axis and notcoaxial with the first axis. A structural member has a first end and asecond end, the first end of the structural member secured to the secondframe member and the second end of the structural member slidablyengaging the guide member between the at least two positions of thefirst frame member. Sufficiently rotating the adjusting member about thefirst axis with respect to the second retainer to actuate the head in adirection away from the second retainer, the resilient device iscompressed between the first retainer and the second retainer, the firstend of the adjusting member abutting the first frame member to supportthe weight of the first frame member and the first compartment. Thesecond end of the structural member substantially constrains movement ofthe first compartment along the second axis between the at least twopositions of the first frame member.

An advantage of the present invention is a vibration isolator having aminimum number of components.

A further advantage of the present invention is a vibration isolatorthat is easily installed in the AHU.

Other features and advantages of the present invention will be apparentfrom the following more detailed description of the preferredembodiment, taken in conjunction with the accompanying drawings whichillustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an overall perspective view of an AHU of the presentinvention;

FIG. 2 is a perspective view of a raceway of the present invention;

FIG. 3 is a cross section of the raceway of the present invention;

FIG. 4 is a cross-section of a raceway frame taken along line 4—4 ofFIG. 1 of the present invention;

FIG. 5 is an exploded perspective view of one end of a raceway split andlifting lug components of the present invention;

FIG. 6 is a perspective view of an assembled raceway split and liftinglug components of the present invention;

FIG. 7 is a perspective view of an assembled raceway splice of thepresent invention;

FIG. 8 is an enlarged, exploded perspective view of an orthogonal cornerof a raceway frame of the present invention;

FIG. 9 is an enlarged, perspective view of the assembled corner of theraceway frame of FIG. 8 of the present invention;

FIG. 10 is an exploded perspective view of a corner assembly of thepresent invention;

FIG. 11 is a perspective view of the assembled corner assembly of FIG.10 of the present invention;

FIG. 12 is a rotated perspective view of the assembled corner assemblyof FIG. 11 to show the tabs of the corner cap member of the presentinvention;

FIG. 13 is an enlarged perspective view of a raceway connected to acorner assembly of the present invention;

FIG. 14 is a sheet metal flat pattern of a fixture of an insulated panelof the present invention;

FIG. 15 is a perspective view of the partially fabricated fixture ofFIG. 14 of the present invention;

FIG. 16 is an exploded perspective view of insulated panels prior toinsertion into adjacent raceway frames of the present invention;

FIG. 17 is a cross section an insulated panel taken along line 17—17 ofFIG. 16 of the present invention;

FIG. 18 is an exploded perspective view of a sloped, insulated roofpanel prior to assembly with a raceway frame of the present invention;

FIG. 19 is a cross section of the assembled insulated roof panel andraceway frame taken along line 19—19 of FIG. 18 of the presentinvention;

FIG. 20 is a cross section of the assembled insulated roof panel andraceway frame taken along line 20—20 of FIG. 18 of the presentinvention;

FIG. 21 is a perspective view of a blower assembly and belt-driven motormounted to an adjustable platform assembly of the present invention;

FIG. 22 is an inverted, exploded perspective view of the platformassembly of the present invention;

FIG. 23 is a partial perspective view of an AHU rail structure housing avibration isolator of the present invention;

FIG. 24 is an elevation view of the vibration isolator taken along line24–24 of FIG. 23 of the present invention;

FIG. 25 is an elevation view of the vibration isolator taken along line25—25 of FIG. 23 of the present invention;

FIG. 26 is an exploded perspective view of adjacent raceway frames,minus corner members, of the present invention;

FIG. 27 is a partial perspective view of raceways of a raceway framesupporting wire ways of the present invention;

FIG. 28 is an elevation view of the sloped roof assembly of FIG. 18 ofthe present invention;

FIG. 29 is a partial perspective view of the sloped roof assemblyinvention; and

FIG. 30 is a perspective view of a component of an AHU supported by arail structure housing a vibration isolator of the present invention.

Wherever possible, the same reference numbers will be used throughoutthe drawings to refer to the same or like parts.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to framing members that are comprised ofinterconnected raceways which are adapted to both structurally andsealingly carry rectangular insulated panels. Having a closed crosssectional profile, the raceway is sufficiently stiff to satisfy the mostrigorous structural loading requirements, while maintaining alightweight construction. The raceway has a single profile that isconfigured to be used regardless of whether the raceway defines a lowerhorizontal, upper horizontal, left vertical or right vertical framemember for surrounding the rectangular panel. The raceway also providesan identical, continuous seam or recess for securing each side of thepanel. Additionally, the raceway may be provided with a universalaperture arrangement adjacent to its ends for use with the appropriateconnectors to permit splicing and/or lifting points at the corners ofthe AHU structure or at any position along the span of the raceway.

The raceway defines a closed geometric profile including a first segmentwhich extends to a first recessed portion, a second segment extending toa second recessed portion, closing portions extending from the first andsecond recessed portions, the closing portions terminating at a flangeportion. The first and second segments have an edge portion and aresubstantially perpendicular to each other. The collective profiledefined by the first segment and first recessed portion is substantiallya mirror image of the collective profile defined by the second segmentand second recessed portion about a plane (plane of symmetry) passingthrough the edge portion that bisects the angle between the first andsecond segments. This symmetry provides an identical, continuous seam orrecess for securing each side of the panel. The flange portion of theraceway when assembled as an upper horizontal frame member secures awire way for providing both a convenient and effective passage forrouting electrical wiring, or other flexible lines associated with AHUoperation, as well as providing peripheral support for a top or ceilinginsulating panel or roof panel. Additionally, the flange portion mayprovide a supplemental peripheral seal between each of the top andbottom, i.e., ceiling and floor, insulated panels.

In other words, the present invention relates to a profile for astructural member for constructing an air handling unit including afirst segment having a first end and a second end, a first recessedportion extending from the second end. A plane of symmetry is coincidentwith the first end at a predetermined angle from the first segment. Asecond segment has a third end that is coincident with the first end anda fourth end, a second recessed portion extending from the fourth end.The second segment and the second recessed portion are symmetrical aboutthe plane of symmetry with the first segment and the first recessedportion, and the first recessed portion extends to a third segment. Thesecond recessed portion extends to a fourth segment, and the thirdsegment and the fourth segment form an edge portion, wherein the firstsegment, the second segment, the first recessed portion, the secondrecessed portion, the third segment, and the fourth segment define aclosed geometry.

In an alternate embodiment, the raceway defines a closed geometricprofile including a first segment which extends to a first recessedportion, a second segment extending to a second recessed portion, athird segment and a fourth segment extending from the first recessedportion and the second recessed portion, respectively, the fourthsegment extending to a third recessed portion, the third recessedportion and the third segment terminating at a flange portion. The firstand second segments have an edge portion and are substantiallyperpendicular to each other. The collective profile defined by the firstsegment, the first recessed portion, and the third segment (notincluding the flange portion) is substantially a mirror image of thecollective profile defined by the second segment, the second recessedportion, and the fourth segment about a plane (plane of symmetry)passing through the edge portion that bisects the angle between thefirst and second segments. This symmetry provides an identical,continuous seam or recess for securing each side of the panel. Theflange portion of the raceway when assembled as an upper horizontalframe member secures a wire way for providing both a convenient andeffective passage for routing electrical wiring, or other flexible linesassociated with AHU operation, as well as providing peripheral supportfor a top or ceiling insulating panel or roof panel. Additionally, theflange portion may provide a supplemental peripheral seal between thetop and bottom, i.e., ceiling and floor, insulated panels.

In other words, an alternate embodiment of the present invention relatesto a profile for a framework for constructing an air handling unitcompartment framework including a plurality of structural members havingopposed ends including a first segment having a first end and a secondend, a first recessed portion extending from the second end. A plane ofsymmetry is coincident with the first end at a predetermined angle fromthe first segment. A second segment has a third end that is coincidentwith the first end and a fourth end, a second recessed portion extendingfrom the fourth end. The first recessed portion extends to a firstclosing position, and the second recessed portion extends to a fourthsegment. The second segment, the second recessed portion and the fourthsegment are substantially symmetrical about the plane of symmetry withthe first segment, the first recessed portion and the third segment. Thethird segment and the fourth segment extend to form an edge portion,wherein the first segment, the second segment, the first recessedportion, the second recessed portion, the third segment, and the fourthsegment define a closed geometry. A plurality of structural fittingseach receive the opposed ends of the plurality of structural members toform at least two frames. Remaining structural members of the pluralityof structural members are interposed between the at least two frames,the opposed ends of the remaining structural members beinginterconnected to the at least two frames.

The present invention further relates to an air handling unitconstruction including a plurality of structural members having opposedends including a first segment having a first end and a second end. Afirst recessed portion extends from the second end, and a plane ofsymmetry is coincident with the first end at a predetermined angle fromthe first segment. A second segment having a third end is coincidentwith the first end and a fourth end, and a second recessed portionextends from the fourth end, the second segment and the second recessedportion being symmetrical about the plane of symmetry with the firstsegment and the first recessed portion. The first recessed portionextends to a third segment, and the second recessed portion extends to afourth segment, the third segment and the fourth segment forming an edgeportion. The first segment, the second segment, the first recessedportion, the second recessed portion, the third segment, and the fourthsegment define a closed geometry. A plurality of structural fittingseach receive opposed ends of the structural members to form at least twoframes, remaining structural members of the plurality of structuralmembers being interposed between the at least two frames. The opposedends of the remaining structural members are interconnected to the atleast two frames to form a framework, and a plurality of panels arereceived by the framework to form an enclosed panel structure.

The raceways can be injected with insulating material to significantlyeliminate the formation of condensation, which could cause corrosion ofthe raceways. The addition of insulating material also increases theefficiency of the heat and cooling system.

An orthogonal corner of the frame structure may be formed by receivingone end of three different raceways in a corner member, each of thethree raceways being secured to the corner member in a mutuallyperpendicular arrangement. The corner member further provides identical,continuous joints with each of the raceways.

The corner member forms a common corner point that extends into threeorthogonal surfaces. Each of the three orthogonal surfaces defines anL-shaped portion, with each L-shaped portion having two legs ofsubstantially equal length. Each leg of one L-shaped portion connects toone leg of each of the other L-shaped portions, each connection betweenadjacent legs defining an edge. The corner member defines three mutuallyperpendicular edges that terminate at the common corner point. Thus, theend of each edge opposite the common corner point terminates at the endsof adjacent legs that are perpendicular to each other, providing twoperpendicular surfaces. One end of each raceway is directed into contactwith the corner member along one of these edges, the connection betweenthe raceway and the two perpendicular surfaces of the corner memberbeing secured by fasteners being directed through apertures formed inmutually aligned arrangements.

In addition to the aperture arrangements, the corner assembly includesan aperture formed in each L-shaped portion preferably adjacent thejunction between edges. The two larger apertures are configured toreceive a lifting lug to permit ease of transport for the assembledframed structure, while the smaller aperture is a tooling aperture foruse during manufacturing of the framed structure.

A corner cap member is preferably of unitary construction and wheninstalled over a corner member that has been secured to threeorthogonally oriented raceways, forms a substantially continuouscoplanar surface with each of the two prominent raceway surfaces of thethree raceways which are visible outside the framed structure of theAHU. The corner cap member covers only a substantially rectangularportion of the corner member that remains exposed after the racewayshave been secured to the corner member. Apertures formed in the cornercap member are substantially coincident with the apertures formed in thecorner member. A pair of opposed tabs extend from upper portions ofadjacent rectangular portions toward each other in a directionperpendicular to its respective surface. Upon installation of the cornercap member over the corner member, the tabs are configured to extendpast their corresponding L-shaped member to provide a continuous jointin a recess formed in two orthogonal raceways for the purpose ofreceiving a weld joint. Generally, the corner cap member edges areadapted to receive a weld joint along the common periphery between thecap member, the raceways and the corner member.

The present invention also relates to providing an insulated panel thatis inserted in a recess formed along the raceway frames. The connectors,panels and raceways define framed structures typically used with AHUs.The insulated panels for use with AHUs are constructed using a minimumof parts and may be sized according to a customer's individual needs todefine virtually any number of different aspect ratios and dimensions,while still complying with structural stiffness standards as well asassembled air leakage standards. Additionally, a single panelconstruction may be employed irrespective of the location of the panelin the AHU. That is, ceiling, wall and floor panel constructions are thesame.

A fixture for securing injected insulation material therein includes acentrally positioned base of the fixture having opposed risers extendingfrom sides of the base in a direction substantially perpendicular to thebase, which risers further extend to inwardly directed coplanar flanges,and opposed ends. A layer of foam tape having opposed adhesive surfacesis applied along the outside surface of each flange for bonding to anexterior skin. This foam tape also presents a low thermal conductivity,and serves as a thermal barrier to conduction. The exterior skin, whichis preferably a substantially flat rectangular plate, is then positionedover the fixture, the length of overhang between the ends of theexterior skin and the corresponding sides and ends of the fixturepreferably being substantially the same. Once the exterior skin isbonded to the fixture by virtue of the foam tape, the assembled exteriorskin, foam tape and fixture collectively define a closed interiorchamber for receiving insulating material therein.

The insulating material is then injected by an injection gun inside thechamber through apertures formed in the exterior skin using a speciallyconfigured press to ensure the fixture and exterior skin aresufficiently supported against the force of the insulating material thatis injected at an elevated pressure level. The volume of the chamber iscalculated prior to the injection operation. A precise amount ofinsulating material is injected into the chamber by correcting for theambient conditions at the time of injection as it is desirable tocompletely fill the chamber with insulating material. Since the flowrate of the injected material through the injection gun is a knownvalue, the duration of flow is the variable parameter which is preciselycontrolled to achieve the proper amount of injected insulation material.Once the injection process is completed and the injected insulatingmaterial has cured, the insulated panel is installed in the AHU framestructure.

Four raceways joined by corner connectors collectively define a racewayframe or structure that surrounds and supports each insulated panel. Toprepare the raceway frame for installation of the insulated panel, alayer of single-sided adhesive foam tape is applied to each of the fourrecessed surfaces along each of the four raceways surrounding the panel.The recessed surfaces define a recessed periphery for sealingly securingthe insulated panel therein. Single sided adhesive tape is used topermit the insulated panel to be easily removed from the framestructure. The insulated panel is then installed into the framestructure, the recessed surfaces of the raceways being configured suchthat the overhangs of the exterior skin are brought into physicalcontact with the recessed periphery defined by the raceways. Theinstallation is the same for both the installation of a top panel or abottom panel. Once the overhangs of the insulated panel are in physicalcontact with the recessed periphery of the frame structure, removablefasteners, such as sheet metal screws, are installed at intervals alongthe overhang using a predetermined range of installation spacing toprovide support and a substantially fluid tight seal between theoverhang of the exterior skin and the recessed periphery of the framestructure.

The present invention also relates to providing a sloped, insulated roofassembly for use with AHUs. The sloped insulated roof assembly is ofunitary construction which preferably comprises two sloped halvesabutting along the mid span of the roofline, typically referred to asthe peak of the roof. Each sloped half includes a fixture and exteriorskin collectively defining a closed chamber for receiving injectedinsulating material under pressure, similar to the construction ofmodular insulated panels secured along the recesses of raceway frames.However, unlike the insulated panel, the sloped half is not constructedof uniform thickness. That is, while the sloped half preferably has ahorizontal ceiling that is substantially coplanar, the thickness of thesloped half measured along the abutting mid span from the ceiling to itsupper surface (the peak) is greater than the thickness of the opposedend of the sloped half measured from the ceiling to its upper surface.The amount of the difference in thickness measurements taken along themid span versus being taken along the end opposite the mid span is afunction of the slope of the roof, preferably at least one quarter of aninch per foot for permitting water drainage.

Extending past the end of the sloped half opposite the mid span alongthe roofline is a retaining portion for securing the sloped half to araceway. The retaining portion is preferably sized to receive theraceway, the retaining portion further extending to a retaining flange.Preferably, the surface of the end of the sloped half and surfaces ofthe retaining portion and retaining flange collectively contact theraceway along its opposed vertical surfaces and along its upper surface.To provide a substantially fluid tight seal between the retainingportion and the raceway, butyl tape may be preferably applied to one ofthe mating surfaces as required prior to assembly.

To assemble the opposed sloped halves, a spliced connection preferablyalong or adjacent the ceiling may be provided, if desired. However, suchreinforcing connections between the sloped halves are not required dueto the vertical support provided by the flange portion of the raceways,as well as support provided by additional walls. The flange portion ofthe raceways defining the outer walls, also referred as the “footprint”of the framed structure, provides a continuous, peripheral supportsurface to the roof assembly. However, since the axis of the roof peakcorresponds to the greater length of a “footprint” of a framedstructure, typically coinciding with the direction of air flow throughan AHU, frequently at least one additional vertically oriented racewayframe, also referred to as a bulkhead, is erected perpendicular to theaxis defined by the roof peak, which provides considerable additionalsupport. To provide a fluid tight seal along the roof peak, sealing tapeor a layer of overlap material may be applied along or secured over theseam, or one of the sloped halves may provide an overlap or anycombination of these constructions can be used.

The present invention also relates to providing an adjustable platformassembly for achieving easily controlled motor belt tensioning/alignmentbetween a motor and blower assembly within an AHU compartment orhousing. To achieve the desired controlled positioning, either the motoror the blower assembly is fixedly secured to support structure withinthe compartment, while the other component is secured to an adjustableplatform assembly that is positionable by means of sliding along thesupport structure. In the preferred embodiment, the blower assembly issecured to the support structure and the motor is secured to theplatform assembly. In this embodiment, opposite the blower assemblyadjacent the platform assembly is a pusher/puller assembly that isfixedly secured to the support structure. The platform assemblypreferably comprises a compact hat section member, including a platformfor securing the motor, opposed standoff members extending from theplatform and opposed flange members extending outwardly from thestandoff members. Each of the flange members of the hat section memberpreferably have a pair of elongated slots formed therein. By looseningfasteners corresponding to each slot that secure the platform assemblyto the support structure, the platform assembly is movable along thesupport structure. The platform of the platform assembly includesmultiple slots formed therein to accommodate different motor mountingarrangements. Extending from an end of the platform adjacent thepusher/puller assembly is a flap member configured to secure a pair ofthreaded blocks preferably positioned along opposite ends of the flapmember. To secure each block, at least one bolt is directed throughapertures formed in the flap member and/or corresponding structure inthe motor base to engage the threaded block. An additional apertureformed in the flap member is aligned with a threaded guide apertureformed in each block to permit access to the guide aperture, each guideaperture to threadedly receive an elongate threaded member from thepusher/puller assembly.

The pusher/puller assembly comprises an angle member having a first anda second leg, the first leg being secured to the support structure. Thevertically extending second leg of the angle member includes twoapertures through which each pass the elongate threaded member. It isrealized that to use the “pusher” capability of the pusher/pullerassembly, a retaining means is required, such as a retaining ring, toreact the compressive forces directed along the threaded members.

In operation, actuation of either or both of the elongate threadedmembers which are each threadedly engaged with the block, urge theplatform assembly into controlled movement. This controlled movement isespecially critical in effecting proper belt tension while maintainingalignment between the sheaves of the motor and blower assembly. Once theelongate members have been sufficiently actuated to provide the desiredpositioning of the platform assembly, the fasteners that pass throughthe elongated slots in the platform assembly flange members are securedto the support structure.

The present invention further relates to providing vibrationallyisolated support between a vibrating assembly of an AHU, such as a fanassembly, that is supported beneath a separate structural frame. Atleast two isolator rails having at least one vertical side are mountedto a top panel which is supported by, i.e., stacked upon, a pre-existingstructural frame. It is understood that the term “structural frame” mayrefer to four interconnected raceways to structurally secure a singleinsulated panel, or more generally, to a plurality of interconnectedraceway frames collectively forming a three dimensional frame structurefor securing a plurality, such as six, insulated panels. Alternately,isolator rails may also be mounted in the floor, or to any structurerequiring vibration isolation and support. The isolator rail connects toa spring comprising a resilient, cupped spring retainer, possibly madeof hard rubber, for securing a lower end of a spring member therein. Thespring retainer has a centrally positioned protrusion opposite itscupped end for engaging an aperture in the isolator rail. An upper endof the spring opposite the lower end is preferably received by a cuppedthreaded spring retainer. The threaded spring retainer has a centrallypositioned threaded aperture for threadedly receiving an adjusting bolttherein. A head of the adjusting bolt has a coaxially aligned threadedaperture for receiving a cap screw therein.

The assembly to be vibrationally isolated is preferably supported by atleast two cross braced spring rails. At least three, and preferably atleast four, vibration isolators are utilized and positioned to provide asufficiently broad support platform for the vibrationally isolatedassembly. At each position for installing a vibration isolator, acorresponding portion of spring rail and isolator rail are verticallyaligned. The cap screw is directed through an aperture in the springrail and placed in threaded engagement with the adjusting bolt to securethe spring isolator to the spring rail. The centrally positionedprotrusion of the spring retainer engages the corresponding aperture tothe isolator rail, the engagement being primarily maintained by theweight of the assembly to be vibrationally isolated.

For the vibration isolator to function as intended, the spring of eachspring isolator must be adjusted to substantially evenly carry thecollective weight of the assembly to be vibrationally isolated andsupporting spring rails. The spring adjustment is achieved by actuatingthe adjusting bolt with respect to the threaded spring retainer suchthat the head of the adjusting bolt moves vertically in a direction awayfrom the threaded spring retainer. As the head of the adjustment boltmoves vertically, it abuts the spring rail. Further actuation of theadjusting bolt with respect to the threaded spring retainer, in effect,compresses the spring, the spring compressive force bearing the weightof the assembly to be vibrationally isolated. Although the weight of thevibrationally isolated assembly is supported once the springs have beensufficiently adjusted, vibrationally isolated lateral support must alsobe provided for stability and to prevent the centrally positionedprotrusion of the spring retainer from possibly “bouncing out” ofengagement with the aperture in the isolator rail. To provide thislateral support, a leg of an angle is secured to the side wall of theisolator rail, the horizontally extended leg of the angle furthersecuring a grommet therein. A bolt is then passed through axiallyaligned apertures formed in the spring rail and the grommet and securedin position by a nut. The grommet provides vibration isolation betweenthe bolt and the angle while the bolt simultaneously provides therequired lateral support for the vibrationally isolated assembly.

One embodiment of an AHU 10 that incorporates the constructions of thepresent invention is depicted in FIG. 1. AHU 10 is an enclosed framedpanel structure 12, or series of interconnected framed panel structures12 which each preferably defines a rectangular compartment that isconfigured to enclose or house components which provide forced air forclimate control in a particular structure. AHU components typicallyinclude motors, heating/cooling coils, and blowers as well as therequired interface connections to effect such climate control. Framedpanel structures 12 have a plurality of insulated panels 300 that areeach structurally and sealingly supported by a raceway frame 22. Eachraceway frame 22 is comprised of a plurality of raceways 20, preferablyfour, that are interconnected by corner members 200.

Referring to FIGS. 2–4, raceway 20 defines a closed geometric profileincluding a first segment 26 which extends to a substantially squaredfirst recessed portion 28, a second segment 30 extending into asubstantially squared second recessed portion 32, a third segment 33extending from first recessed portion 28, a fourth segment 34 extendingfrom second recessed portion 32, a third recessed portion 35 extendingfrom fourth segment 34, third segment 33 and third recessed portion 35terminating at a flange portion 36. First and second segments 26, 30have an edge portion 38 and are substantially perpendicular to eachother. The collective profile defined by first segment 26 and firstrecessed portion 28 is a mirror image of the collective profile definedby second segment 30 and second recessed portion 32 about a plane 40(plane of symmetry) passing through edge portion 38 that bisects angle39 between first and second segments 26, 30. Preferably, first andsecond segments 26, 30 are orthogonal, thus, angle 39 is ninety degreesand plane 40 is forty five degrees from each of first and secondsegments 26, 30. Similarly, first and fourth segments 33, 34 arepreferably substantially perpendicular to each other, and flange portion36 is substantially parallel to first segment 26 and fourth segment 34.Since each raceway in a single compartment, enclosed framed panelstructure connects to a corner member of the structure, each raceway canstructurally support two adjacent insulated panels. By virtue of thesymmetry of raceway 20, a single raceway profile may be used for eachraceway 20 that is used to construct the structural framework for AHU 10to provide identical, continuous peripheral seams or recesses forstructurally securing each side of each insulated panel.

For example, referring to FIG. 16, two adjacent raceway frames 22 eachreceiving the corresponding insulated panel 300 are shown, which racewayframe 22 comprising raceways 20 that are interconnected by cornermembers 200. Common to each raceway frame 22 is the raceway 20 which islocated at the common corner, which raceway being referred to as acommon raceway 21. One raceway frame 22 peripherally receives each ofthe four sides of the exterior skin 316 of its corresponding insulatedpanel 300 in second recessed portion 32 formed in each raceway 20. Whilethe other raceway frame 22 also peripherally receives the four sides theexterior skin 316 of its corresponding insulated panel 300, two of thefour sides of the exterior skin 316 are received in first recessedportion 28 that is formed in two of the raceways 20, and the remainingtwo sides of the exterior skin 316 are received in second recessedportion 32. This means that common raceway 21 (and the other verticallyoriented raceway 20 positioned on the far left hand portion of FIG. 26)simultaneously secures one side of each of two different insulatedpanels 300, one side of insulated panel 300 being supported in firstrecessed portion 28, and one side of insulated panel 300 being supportedin second recessed portion 32. Referring to FIG. 26, which is anenlarged exploded view of FIG. 16 without the corner members 200 andinsulated panels 300 to more clearly show the raceway 20 orientations,the raceway construction is shown. A first phantom outline 70 isprovided to show the raceway recesses of raceway frame 22 that securethe insulated panel 300 when installed. A second phantom outline 72 isprovided to show the raceway recesses of raceway frame 22 that securethe insulated panel 300 when installed. Based on the construction of theraceways 20, including the symmetry for each raceway over the collectivelength of the first segment 26 and the first recessed portion 28 ascompared to the collective length of the second segment 30 and thesecond recessed portion 32 about the plane of symmetry 40 as previouslydiscussed, the raceway profile may be configured for use with AHU 10regardless of whether the raceway 20 defines a lower horizontal, upperhorizontal, left vertical or right vertical frame member for surroundingand structurally supporting the rectangular insulated panel 300.

Referring to FIGS. 8–9, the continuous peripheral seams or recesses forstructurally securing each side of each insulated panel is shown byconstructing a corner of a structural frame using three raceways 20interconnected by corner assembly 204 which is comprised of a cornermember 200 that is overlaid by a corner cap member 202. Upon assembly ofraceways 20 to corner assembly 204, a continuous second recessed portion32 is formed along two of the raceways 20, although at a corner 27 ofthe second recessed portion 32, a tab 228 of corner cap member 202provides the “bridge” between the junction of two raceways 20 to ensurethe second recessed portion 32 is, in fact, continuous. To provide acontinuous seam along the flange portion 36 of adjacent horizontalraceways 20, it is necessary to provide chamfered edges 37, which resultin an edge portion 38.

Referring to FIG. 4, raceway frames 22 provide a substantially fluidtight seal between each external skin 316 of insulated panel 300 andeach corresponding first and second recessed portion 28, 32 by a layerof resilient gasket material 324, such as a closed cell foam gasket orany similar resilient material that is compatible for use with AHUs thatfunctions in a similar manner. Gasket material 324 preferably has asingle side adhesive layer which is applied to the portion of first andsecond recessed portion 28, 32 of raceway frame 22 that physicallycontacts external skin 316. Applying the single-side adhesive layer ofthe gasket material 324 against the corresponding recess of the racewayframe not only secures the gasket material 324 to the raceway frame, butpermits convenient, non-marring removal of the insulated panel 300 fromthe raceway 22. Fasteners, such as sheet metal screws (not shown) areinstalled at predetermined increments as required with the fastenercollectively passing through the external skin 316, gasket material 324,and the corresponding first recessed portion 28 or second recessedportion 32. By applying a predetermined range of torque to install thefastener, the external skin 316 and the corresponding first recessedportion 28 or second recessed portion 32 are brought togethersufficiently to subject the gasket material 324 to a compressive loadsuch that a substantially leak tight seal is achieved.

Referring to FIGS. 2–4 and 27, flange portion 36 provides a closedgeometry for raceway 20. This closed geometry provides the raceway 20with enhanced stiffness and strength while maintaining a lightweightconstruction. To further strengthen and stiffen the raceway, the twooverlapping layers of material comprising the flange portion 36 of theraceway 20, preferably stainless steel, are preferably fixedly joinedtogether, such as by weld, adhesive or chemical bond, fastener, clamp orother method known in the art, either continuously or at predeterminedintervals along its length. Flange portion 36 may be employed to provideadditional structural support for insulated panel 300, or an insulatedroof assembly 400 which is discussed in further detail below, when theinsulated panel 300 is used as a top panel or ceiling (FIG. 4).Alternately, further referring to FIG. 4, flange portion 36 may beemployed to provide additional support when the insulating panel 300 isused as a bottom or floor panel. However, to support a floor panel,fasteners (not shown) may be installed through the flange portion 36 andthen through a fixture 302 of insulating panel 300, if desired. Othermethods may be used to secure flange portion 36 to fixture 302 ofinsulating panel 300, although non-permanent methods such as fastenersare preferred to permit disassembly and removal of the insulating panel300. It is appreciated that in addition to providing structural support,flange portion 36 provides an opportunity for a supplemental sealbetween raceway 20 and insulated panel 300, especially if sufficientproximity between the surface of insulated panel 300 and flange portion36 is achieved, such as when a layer of gasket material 324 is appliedbetween fixture 302 and flange portion 36 to bridge the gap therebetween.

Referring to FIG. 27, flange portion 36 of raceway 20 also structurallysupports internal AHU components, such as wire ways 64, which compriseflanged trough members 66 that likewise support flanged channels 68 thattypically extend transverse to flanged trough members 66. Wire ways 64can provide convenient, non-intrusive access for electrical wiring orother small, flexible connections for use with the AHU. By supportingthe wire ways 64 beneath the flange portions 36 of the upper horizontalraceway frame 22, access problems that may be otherwise encountered whenservicing the AHU are minimized.

Referring to FIGS. 5–7, due to size constraints, typically related tomaximum shipping dimensions for transport by truck, it is oftennecessary to sever ends of the raceways, or to provide shortenedraceways in anticipation of shipping, which severed or discontinuousends formed in the raceways being referred to as “splits.” Such splitsinterrupt the structural integrity of the raceways. However, due to theenhanced structural strength of the raceways, which results from theclosed geometry profile of the raceways and also the use of metal,preferably stainless steel, to construct the raceways, structuralfittings may be attached adjacent to a split line 60. In other words,the split line of the raceways of the present invention may be utilizedto attach structural fittings for use with lifting at least the portionof the AHU structure that has been “split,” and may be used to help liftthe entire AHU when assembled with these structural fittings.

A universal aperture arrangement 42 is formed adjacent the split line 60of the raceway 20 that is compatible with the structural fittings.Preferably, the raceways 20 involved with lifting are located along thelower horizontal frame. A reinforcing member 44, preferably resembling a“C” is directed into the end of raceway 20 corresponding to split line60 and slid into raceway 20 until the apertures 46 formed in reinforcingmember 44 are aligned with the corresponding apertures in universalaperture arrangement 42. A lifting lug half 48 which is preferablystructurally reinforced by gussets 50, has apertures 46 formed inlifting lug half 48 that are also compatible with universal aperturearrangement 42. Once apertures 46 of lifting lug half 48 are directedinto alignment with previously aligned apertures of reinforcing member44, a fastener 54, such as a bolt, is directed through the alignedapertures such that fastener 54 collectively passes through lug half 48,raceway 20 and reinforcing member 44. A fastener retainer 56, such as anut, is directed into threaded engagement with fastener 54, and theremaining fasteners 54 and fastener retainers 56 are similarly installedto a predetermined torque such that a portion of raceway 20 adjacentsplit line 60 is structurally reinforced between gusset 50 andreinforcing member 44. Alternately, reinforcing member 44 may beelongated to structurally bridge between two abutting raceways 20, whichreinforcing member 44 further having a second set of apertures 46 toalign with the universal aperture arrangement 42 of the second raceway20 to provide a stronger joint for lifting the AHU portion or entire AHU10. To provide lifting access, lifting lug half 48 or combined liftinglug 58, which is two abutting lifting lug halves 48 (FIG. 6), anenlarged lug aperture 52 is formed in lifting lug half 48 for receivinga fitting, such as a shackle (not shown) attached at the end of a chainor cable that is associated with a lifting device such as a crane (notshown) and other related lifting hardware intended to more evenlydistribute the aggregate load of the AHU, such as spreader bars.Alternately, it may be desirable to join abutting raceways along asplice line 62 by simply placing a peripheral weld along splice line 62(FIG. 7).

Although the universal aperture arrangement 42 is preferably formedadjacent the split lines 60 of the raceways 20, it is appreciated thatthe universal aperture arrangement 42 is also compatible with theaperture arrangement 24, such that the universal aperture arrangement 42may be used with all structural fittings, if desired.

To increase the efficiency of the heating and cooling system, raceways20 can be injected with insulating material (not shown). Since theinsulating material is preferably applied to substantially completelyfill the interior of the raceways, the formation of condensation in theraceway, which is a major cause of corrosion, is likewise significantlyeliminated.

Referring to FIGS. 8–13, an orthogonal corner of the frame structure ofAHU 10 is formed by receiving one end of three different raceways 20 incorner assembly 204 (FIG. 8), each of the three raceways 20 beingsecured to the corner assembly 204 in a mutually perpendiculararrangement. The corner assembly 204 further provides identical,continuous joints with each of the raceways 20 (FIG. 9). The cornerassembly 204 comprises a corner member 200 that is coupled with a cornercap member 202. Corner member 200 is preferably of unitary construction,having common aperture arrangements 218 formed in orthogonally arrangedportions 201 of corner member 200 that are compatible with aperturearrangements 24 formed adjacent ends 25 of raceways 20, whereby thecorner members 200 and raceways 20 define the frame structure for theAHU. In other words, due to the aperture arrangements 218 in the cornermember 200 being compatible with the aperture arrangements 24 in theraceways 20, any end 25 of raceway 20 can be secured to anycorresponding portion 201 of corner member 200. However, to ensurecontinuous joints with each of the raceways are achieved, the aperturearrangement 218 formed in the vertically oriented portion 201 of cornermember 200 can be configured such that the vertically oriented portion201 only mates with the aperture arrangement 24 of a vertically orientedraceway 20. Similarly, the aperture arrangement 218 formed in opposedhorizontally oriented portions 201 of corner member 200 can beconfigured such that the horizontally oriented portion 201 only mateswith the aperture arrangement of a horizontally oriented raceway 20.

Once corner member 200 is formed, such as by bending a metal flatpattern, corner member 200 forms a common corner point 206 that extendsinto three substantially orthogonal surfaces 208. Each of the threeorthogonal surfaces 208 defines an L-shaped portion 210, with eachL-shaped portion 210 having two legs 212 of substantially equal length.Each leg 212 of one L-shaped portion 210 connects to one leg 212 of eachof the other L-shaped portions 210, each connection between adjacentlegs 212 defining an edge 214. In a preferred embodiment, one L-shapedportion 210 is comprised of two opposed halves brought together as aresult of bending a single piece of sheet metal, the two pieces beingseparated by a gap 236 (FIG. 12). If desired, gap 236 can be welded orjoined together by methods known in the art. Corner member 200preferably defines three mutually perpendicular edges 214 that terminateat common corner point 206. Thus, the end 216 of each edge 214 that isopposite the common corner point 206 terminates at the ends of adjacentlegs 212 which are perpendicular to each other, the legs 212 providingtwo perpendicular, or orthogonal, surfaces 208.

While legs 212 of corner member 200 are preferably identical, a pair ofrecesses 213 are formed adjacent the juncture of the legs 212 ofadjacent L-shaped portions 210 for use with corner cap member 202 whichwill be discussed in further detail below. Aperture arrangements 218 areformed in each leg 212 adjacent end 216 of edge 214. Collectively, theportion of adjacent legs 212 defining perpendicular surfaces 208 thatare connected by corner 214, including aperture arrangements 218adjacent end 216, comprises an orthogonal portion 201 of corner member200. Thus, corner member 200 has three orthogonal portions 201, eachorthogonal portion 201 for structurally receiving one end of raceway 20.Thus, referring back to FIG. 8, an end 25 of each raceway 20 is directedover a corresponding orthogonal portion 201 of corner member 200 along acorresponding edge 214 to form a connection. The connection that isformed between each raceway 20 and the two perpendicular surfaces 208defined by orthogonal portion 201 of the corner member 200 is secured byfasteners (not shown) being directed through respective, mutuallyaligned aperture arrangements 24, 218. This connection between theraceways 20 and the corner member 200 is of sufficient strength to serveas a lifting point for the AHU.

To provide convenient lifting access of the corner member 200, a pair ofenlarged lifting apertures 220 are formed along the respective junctionsof adjacent L-shaped portions 210 which are likewise positioned adjacentcommon corner point 206. Lifting apertures 220 are configured to readilyreceive a lifting shackle or other conventional lifting fitting for easeof transport of the assembled framed structure. In addition to thelifting apertures 220 which are each formed in a different orthogonalsurface 208, a tooling aperture 222 is formed in the remainingorthogonal surface 208 adjacent the juncture of the correspondingL-shaped portion that is adjacent common corner point 206. Toolingaperture 222 is configured to receive a fitting on a tooling structure(not shown) to assist with fabrication of the framed structure.

Corner cap member 202 is preferably of unitary construction, such as bybending a metal flat pattern, and when installed over corner member 200that has been secured to three orthogonally oriented raceways 20, formsa substantially continuous coplanar surface with each of the first andsecond segments 26, 30 of raceways 20 which are visible outside theframed structure of the AHU. The corner cap member 202 is comprised ofthree interconnected, orthogonal, rectangular portions 232 havingorthogonal surfaces 234. An enlarged aperture 224 is formed in each oftwo adjacent rectangular portions 232, and an aperture 226 is formed inthe remaining rectangular portion 232 such that when corner cap member202 is installed over corner member 200, the apertures formed in thecorner cap member 202 are substantially coincident with the aperturesformed in the corner member 200. In other words, the pair of liftingapertures 220 and the tooling aperture 222 formed in corner member 200remain accessible after the corner cap member 202 is installed over thecorner member 200. A pair of substantially rectangular tabs 228 protrudefrom upper portions of adjacent rectangular portions 232 toward eachother in a direction perpendicular to its respective surface 234 so thatwhen the corner cap member 202 is installed over corner member 200, tabs228 are received adjacent recess 213 of corner member 200 (FIG. 12).When corner cap assembly 204 is connected to three raceways 20 (FIG. 9),tab 228 ensures second recessed portion 32 adjacent corner 27 iscontinuous.

Rectangular portions 232 of corner cap member 202 are sized to cover thecorresponding substantially rectangular portions of the orthogonalsurfaces 208 of the corner member 200 that remain exposed after theraceways 20 have been secured to the corner member 200. Similarly, tabs228 of corner cap member 202 are sized to cover the exposed portions offirst and second recessed portions 28, 32 remaining after theorthogonally oriented raceways 20 are connected to the corner member200. Thus, by covering the exposed portions remaining after the raceways20 are connected to the corner member 200, the raceway surfaces andrecesses along abutting raceways are substantially continuous. Ifdesired, the seams defined by the assembly of the raceways 20 with thecorner assembly 204 can be welded, including the seam around theperiphery of tab 228 (FIG. 13).

Referring to FIGS. 14–17 insulated panel 300 is provided for insertionin the first and/or second recessed portions 28, 32 formed along theraceways 20 that are interconnected by connectors to form framedstructures used with AHUs. Insulated panel 300 of the present inventionis constructed using a minimum of parts and may be sized according to acustomer's individual needs to define any number of different aspectratios and dimensions, preferably down to at least one inch increments,while still complying with structural stiffness standards as well asassembled air leakage standards. Additionally, a single panelconstruction may be employed irrespective the location of the panel inthe AHU. That is, ceiling, wall and floor panel constructions are thesame.

Fixture 302 is preferably constructed of sheet metal, although othermaterials for use in HVAC systems that are sufficiently formable ormoldable with sufficient strength may also be used. Fixture 302comprises a centrally positioned base 304 having opposed risers 306extending from sides of base 304 in a direction perpendicular to base304, which risers 306 further extend to inwardly directed coplanarflanges 308, and opposed ends 310. When opposed ends 310 are rotatedinto a desired position, which is substantially perpendicular to base304, the assembled fixture 302 resembles a rectangular block with anopening into the block due to the space between opposed flanges 308. Alayer of foam tape 312, such as polyethylene tape, having opposedadhesive layers 314 is applied along outside surface 311 of each flange308 for bonding fixture 302 to the exterior skin 316. This foam tape 312also has a low thermal conductivity, and serves as a thermal barrier toconduction. Alternately, other bonding methods or materials may beemployed having similar physical properties. Exterior skin 316, which ispreferably a substantially flat rectangular plate, is then positionedover fixture 302, the length of overhang 318 between the ends of theexterior skin 316 and the corresponding sides and ends of the fixture302 preferably being substantially the same. In other words, the fixture302 is preferably substantially centered with respect to the exteriorskin 316. Once the exterior skin 316 is bonded to the fixture 302 byvirtue of the tape 312, the assembled exterior skin 316, tape 312 andfixture 302 collectively define a closed interior chamber 320 forreceiving insulating material 322 therein.

The insulating material 322 is injected by an injection gun (not shown)inside the chamber 320 through apertures (not shown) formed in theexterior skin 316 using a specially configured press to ensure thefixture 302 and the exterior skin 316 are sufficiently supported againstthe force of the insulating material 322 that is injected at an elevatedpressure level. The volume of the chamber 320 is calculated prior to theinjection operation. A precise amount of insulating material 322 isinjected into the chamber 320 by correcting for the ambient conditionsat the time of injection as it is desirable to completely fill thechamber 320 with insulating material 322. Since the flow rate of theinjected insulating material 322 through the injection gun is a knownvalue, the duration of flow is the variable parameter which is preciselycontrolled to achieve the proper amount of injected insulation material322. To provide a favorable bonding interface between the inner surfacesof the chamber 320 and the expanding, injected insulating material 322,the press platens that secure the exterior skin 316 are heated,preferably up to about 100° F. Once the injection process is completedand the injected insulation material 322 has cured, the insulated panel300 is installed in the AHU frame structure.

Four raceways 20 joined by corner members 200 collectively define araceway frame 22 that surrounds and supports each insulated panel 300.To prepare the raceways 20 for installation of the insulated panel 300,a layer of single sided adhesive foam tape 324 (FIG. 4) is applied toeach of the four first and/or second recessed portions 28, 32 along eachof the four raceways 20 surrounding and supporting the insulated panel300. The first and second recessed portions 28, 32 define a recessedperiphery for sealingly securing the insulated panel 300 therein. Singlesided adhesive tape 324 is used to permit the insulated panel 300 to beeasily removed from the raceway frame 22. The insulated panel 300 isthen installed into the raceway frame 22, the first and second recessedportions 28, 32 of the raceways 20 being configured such that theoverhangs 318 of the exterior skin 316 are brought into physical contactwith the recessed peripheral surfaces defined by the first and secondrecessed portions 28, 32 formed in the raceways 20. The installation ofinsulated panel 300 is the same irrespective the orientation of theinstalled insulated panel 300. In other words, installations of a toppanel, a side panel or a bottom panel are identical. Once the overhangs318 of the insulated panel 300 are brought into physical contact withthe recessed periphery defined by the first and second recessed portions28, 32 formed in the frame structure, removable fasteners (not shown),such as sheet metal screws, are installed at intervals along theoverhang 318 using a predetermined range of installation spacing toprovide support and a substantially fluid tight seal between theoverhang 318 of the exterior skin 316 and the first and second recessedportions 28, 32 of the raceway frame 22.

The construction of the insulated panel 300 of the present invention islightweight, yet extremely strong. Due to the increased stiffness andstrength, panels may preferably be fabricated up to at least 60 inchesin width, which is a significant improvement over the 48 inches employedin known insulated panel constructions, and lengths up to about 120inches can be fabricated, while meeting current strength/deflectionrequirements.

In a preferred embodiment, upon assembly of the raceway frame, includingassembly of the insulated panels onto the raceway frame, insulatingmaterial is injected inside the connected components through at leastone of the lifting lug apertures in the corner members. Preferably,insulating material is injected at each corner member. Not only doesthis substantially fill the connected components, but it also enhancesthe connection between the raceway frame and the insulated panel, asinsulating material can flow along the interface between the insulatedpanel and the raceways through the fastener apertures.

Referring to FIGS. 18–20 and 28–29, insulated roof assembly 400 providesa sloped roof surface for use with AHU structures of the presentinvention to prevent the formation and accumulation of standing water onthe top of the AHU structures which are installed outside and subjectedto the rigors of environmental exposure, such as rain or snow. Insulatedroof assembly 400 is preferably of unitary construction comprising twosloped halves 402 abutting along the mid span 404 of the roofline,typically referred to as the peak of the roof. Each sloped half 402includes a fixture 406 and an exterior skin 408, similar to thatpreviously discussed for insulating panel 300.

Fixture 406 is preferably of unitary construction and comprises a base407 which forms a substantially coplanar surface that defines ahorizontal ceiling 414 when roof assembly 400 is installed over the AHUframe structure, which frame structure possibly including severalinterconnected raceway frames 22. Base 407 extends outwardly to opposedends 418, which ends 418 extend toward exterior skin 408 in a directionthat is preferably substantially perpendicular to base 407. Ends 418further extend to outwardly extending opposed flanges 419 that aresecured to a retaining portion 422 of exterior skin 408 (FIG. 29). Themeans of bonding flanges 419 to retaining portion 422 may includefasteners, welding, adhesive, or any suitable method of joining twosurfaces known in the art. Additionally, base 407 also extends toopposed side flanges 426, which flanges 426 extend toward exterior skin408 in a direction that is preferably substantially perpendicular tobase 407. Flanges 426 are secured to corresponding opposed flanges 428of exterior skin 408 by any similar method previously described that maybe employed to secure flange 419 and retaining portion 422 of exteriorskin 408.

Exterior skin 408 is preferably of unitary construction and extendsoutwardly from mid span 404 defining a pair of sloped surfaces 415 thattransition to opposed retaining portions 422, which retaining portions422 further extend to corresponding retaining flanges 424 that aresubstantially perpendicular to retaining portions 422. Retaining portion422 and retaining flange 424 are configured to conformally engagerespective portions of first segment 26 and second segment 30 ofraceways 20 of raceway frame 22 when roof assembly 400 is installed ontoraceway frame 22. In addition to retaining portion 422 and retainingflange 424, portions of fixture 406 also conformally engagecorresponding portions of raceway frame 22 when roof assembly 400 isinstalled onto raceway frame 22. That is, base 407 engages flangeportion 36 such that flange portion 36 provides significant peripheralstructural support of base 407, end 418 engages third segment 33, andflange 419, which is connected to retaining portion 422 engages firstsegment 26. In other words, each opposed end of roof assembly 400adjacent retaining portion 422, collectively engages, at leastpartially, four different surfaces of the raceway frame 22. If desired,to help render the connection between retaining portion 422 and adjacentsurfaces of roof assembly 400 and raceway frame 22 substantially fluidtight, a filler material 430, such as a compatible caulk material, maybe applied in and along first recessed portion 28, and may further beapplied along first segment 26, second segment 30, third segment 33, andalong flange portion 36. Alternately, or additionally, tape, such asbutyl tape, may be used to help provide the substantially fluid tightseal.

In addition to exterior skin 408 extending to opposed retaining portions422, exterior skin 408 also extends to opposed flanges 428 which aresubstantially perpendicular to corresponding sloped surfaces 415.Flanges 428 overlap and substantially cover corresponding flanges 426 offixture 406. When roof assembly 400 is installed onto raceway frame 22(FIG. 19), flange 428 is placed in conformal contact with third segment33, although a portion of flange 426, which portion that is notphysically separated from third segment 33 by flange 428, is bothadjacent to and in fluid communication with third segment 33. Further, aportion of base 407 of fixture 406 is also placed in conformal contactwith flange portion 36 of raceway frame 22. If desired, to help renderthe connection between both flange 428 of exterior skin 408, and flange426 and base 407 of fixture 406, and first recessed portion 28, thirdsegment 33, and flange portion 36 of raceway 20 of raceway frame 22,filler material 430 may be applied in and along first recessed portion28, third segment 33 and flange portion 36. Preferably, a sufficientamount of filler material 430 is applied in first recessed portion 430to more than substantially fill first recessed portion 430 such thatmoisture will not collect and accumulate along first recessed portion28. In other words, it is preferable to provide a sufficient amount offiller material 430 to establish a sloped region 432 such that moistureflows away by force of gravity from the region above first recessedportion 28. Alternately, skin 408 may be configured to protrudeoutwardly to provide a retaining portion and retaining flange that isnot only similar to retaining portion 422 and retaining flange 424, butpreferably continuous with retaining portion 422 and retaining flange424 so that first segment 26 is entirely covered by this alternate,continuous construction of retaining portions and retaining flanges ofroof assembly 400.

Similar to insulated panel 300, roof assembly 400 defines a closedchamber 410 for receiving injected insulating material 412 therein. Thatis, upon assembling fixture 406 to exterior skin 408, the collectiveinterfacing surfaces including sloped surfaces 415 and flanges 428 ofexterior skin 408, and base 407, ends 418, and flanges 426 of fixture406 define closed chamber 410. For similar reasons of additionalstiffness and strength, as well as enhanced insulating properties forinsulated panel 300, insulating material 412 is injected inside closedchamber 410 of roof assembly 400 in a manner substantially similar tothat previously discussed for insulating panel 300.

Although the unitary construction of roof assembly 400 has enhancedmechanical stiffness and strength, flange portion 36 of raceway frame 22provides a significant amount of continuous, vertical support along theperiphery of base 407 of fixture 406. Optionally, additional verticalsupport may be provided for roof assembly 400 by a bulkhead 434 (FIG.18). Bulkhead 434 is a vertically oriented structural member that ispositioned transverse to the direction of forced air flow in an AHUstructure. Therefore, the addition of bulkhead 434 provides verticalstructural support along a portion of the entire width of roof assembly400 that coincides with the bulkhead 434 contacting the base 407 of theroof assembly 400, in addition to the peripheral support provided by theflange portion 36.

An important advantage of the roof assembly 400 of the present inventionis its unitary construction. While the unitary construction of the roofassembly 400 provides enhanced structural stiffness and strength, flangeportion 36 of raceway frame 22 provides significant peripheral,structural support, as well as the additional support provided by anadditional bulkhead 434, or even bulkheads 434, as previously discussed.However, if special circumstances require dividing the roof assemblyinto multiple segments, such as sloped halves 402, a spliced connection(not shown), such as along mid span 404, may be formed to bridge thedivided halves 402.

Referring to FIGS. 21–22, an adjustable platform assembly 500 isprovided for achieving easily controlled motor belt tensioning/alignmentbetween a motor 515 and blower assembly 502 within an AHU compartment orhousing. Typically, the source of forced air for an AHU is provided byblower assembly 502 having a bladed arrangement that is rotatablycarried about a shaft 504, which blower assembly 502 being securedwithin the compartment. A sheave 510 that is secured to shaft 504 of thebladed arrangement is typically urged into rotational movement byanother sheave 512 which is secured to a shaft 514 of motor 515 by abelt 516 that is maintained in mutual non-slipping frictional contactwith the peripheral grooves of sheaves 510, 512. For proper operation,sheaves 510, 512 must be maintained in proper alignment with each otherand sufficient tension in belt 516. Thus, either motor 515 or blowerassembly 502 must be properly positioned with respect to each other toachieve these objectives. Complicating matters is the fact that in anAHU, motor 515 and blower assembly 502 are typically positioned within acompact, closed compartment leaving little room to effect suchadjustments.

To achieve the desired controlled positioning, blower assembly 502 maybe fixedly secured to support structure 508 within the AHU compartment.Adjacent blower assembly 502 is adjustable platform assembly 500 that ispositionable by means of sliding along the support structure 508.Opposite blower assembly 502 adjacent platform assembly 500 is apusher/puller assembly 520 that is fixedly secured to support structure508. Platform assembly 500 preferably comprises a compact hat sectionmember 501, including a platform portion 522 for securing motor 515,opposed standoff members 524 extending from platform portion 522 andopposed flange members 526 extending outwardly from standoff members524. However, it is understood that platform assembly 500 may also beconfigured to adjustably secure blower assembly 502 instead of motor515, if desired. Each of the flange members 526 of hat section member501 preferably have a pair of elongated slots 528 formed therein. Byloosening fasteners corresponding to each slot 528 that secure theplatform assembly 500 to support structure 508, platform assembly 500 ismovable along support structure 508. Platform portion 522 of platformassembly 500 includes multiple slots 532 formed therein to accommodatedifferent motor mounting arrangements. Extending from an end of platformportion 522 adjacent the pusher/puller assembly 520 is a flap member 534configured to secure a pair of threaded blocks 536 preferably positionedalong opposite ends of flap member 534. To secure each block 536, atleast one bolt 538 is directed through apertures 540 formed in flapmember and/or corresponding structure in platform portion 522 to engagethreaded block 536. An additional aperture 544 formed in flap member 534is aligned with a threaded guide aperture 546 formed in each block 536to permit access to the guide aperture 546, each guide aperture 546 tothreadedly receive an elongate threaded member 548 from pusher/pullerassembly 520.

Pusher/puller assembly 520 comprises an angle member 550 having a firstleg 552 and a second leg 554, first leg 552 being secured to supportstructure 508. Vertically extending second leg 554 of the angle member550 includes two apertures 556 through which each pass elongate threadedmember 548. It is realized that to use the “pusher” capability of thepusher/puller assembly 520, a retaining means (not shown) is required,such as a retaining ring, to react the compressive forces directed alongthe threaded members 548. In an embodiment of pusher/puller assembly520, the retaining means may be secured to threaded member 548 adjacentsecond leg 554 opposite the head of threaded member 548 such that secondleg 554 is interposed between the retaining means and the head of thethreaded member 548 to achieve this “pusher” capability.

In operation, actuation of either or both of elongate threaded members548 which are each threadedly engaged with block 536, urge platformassembly 500 into controlled movement along support structure 508. Thiscontrolled movement is especially critical in effecting proper belttension while maintaining alignment between sheaves 510, 512 of motor515 and blower assembly 502. Once elongate threaded members 548 havebeen sufficiently actuated to provide the desired positioning ofplatform assembly 500, the fasteners that pass through elongated slots528 in flange members 526 of platform assembly 500 are secured tosupport structure 508. Once these fasteners are secured in slots 528,the position of motor 515, and thus, of sheave 512, are fixed withregard to sheave 510 of blower assembly 502. If the heads of fasteners558 that are positioned in slots 528 to permit sliding movement of theplatform assembly 500 and threaded slots 548 are similarly sized, asingle tool, such as a wrench, or a ratchet with the properly sizedsocket may be used to effect alignment and/or tension control of belt516. It is appreciated that if properly done, such alignment/tensioncontrol may only require one hand, which would enable satisfactoryaccess within the tight quarters of an AHU compartment. By periodicallymonitoring the alignment of sheaves 510, 512 as well as the tension inbelt 516 using a conventional belt tension gauge, which monitoring beingperformed as part of routine maintenance, such as fan bearinglubrication, problems associated with sheave alignment and belt tensionshould be significantly reduced, if not virtually removed.

Referring to FIGS. 23–25 and 30, is a vibration isolator 600 forproviding vibrationally isolated support between a vibrating means of anAHU or AHU component, such as a fan assembly, that is supported beneatha separate structural frame. At least two isolator rails 602 or framemembers having at least one vertical side 604 are mounted to a top panel(not shown) which is supported by, i.e., stacked upon, a pre-existingstructural frame. Alternately, isolator rails 602 may also be mounted inthe floor, or to any structure requiring vibration isolation andsupport. Isolator rail 602 connects to a cupped spring retainer 606,preferably of unitary construction and preferably formed from aresilient material, possibly made of hard rubber, for securing a lowerend 614 of a spring 618 therein. It is to be understood that the spring618 can be constructed of a suitable resilient material or an aircylinder. Spring retainer 606 preferably has a centrally positionedprotrusion 608 opposite its cupped end 610 for engaging an aperture 612in the isolator rail 602. An upper end 616 of spring 618 opposite itslower end 614 is preferably received by a cupped threaded springretainer 620. Threaded spring retainer 620 has a centrally positionedthreaded aperture 622 for threadedly receiving an adjusting ortensioning member 624, such as a bolt or other elongate fastener, and ispreferably of unitary construction therein. Since spring retainer 620may be fabricated from standard bar stock and requires only forming acapped portion and tapping a thread to receive adjusting or tensioningmember 624, and possibly forming flats to receive a wrench to controlrotation of the spring retainer 620 in operation, such few standardmachining operations are not considered sufficient to classify springretainer 620 a specially machined component. A head 626 of adjusting ortensioning member 624 has a coaxially aligned threaded aperture 628 forreceiving a cap screw 630 or locking fastener therein. Head 626preferably defines a number of parallel flats, such as a hexagon, toreceive a wrench to control rotation of the adjusting or tensioningmember 624 in operation.

The cap screw 630 operates to prevent the adjusting member 624 fromrotating. Upon head 626 of adjusting member 624 abutting a spring rail603 or frame member that supports the AHU or assembly that is to bevibrationally isolated, cap screw 630 is directed through an aperture632 in spring rail 603 and into threaded engagement with a threadedaperture 628 formed in head 626 of adjusting member 624. The cap screw630 is then actuated in a direction so that the head of cap screw 630abuts spring rail 603. The cap screw 630 is further actuated until thehead of cap screw 630 sufficiently compresses the material of springrail 603 adjacent aperture 632 between the head 626 of adjusting member624 and the head of cap screw 630 to lock the adjusting member 624 inposition.

The assembly to be vibrationally isolated is preferably supported by atleast two cross braced spring rails 603, the cross-bracing preferablyprovided at each end of spring rails 603 by, for example, an end rail605. At least three, and preferably at least four, vibration isolators600 are utilized and positioned to provide a sufficiently broad supportplatform for the vibrationally isolated assembly. At each position forinstalling vibration isolator 600, a corresponding portion of springrail 603 and isolator rail 602 are vertically aligned. Cap screw 630 isdirected through an aperture 632 in spring rail 603 and placed inthreaded engagement with threaded aperture 628 in head 626 of adjustingmember 624 to secure spring 618 to spring rail 603. Centrally positionedprotrusion 608 of spring retainer 606 engages aperture 612 in isolatorrail 602, the engagement being primarily maintained by the weight of theassembly to be vibrationally isolated. Preferably protrusion 608 issubstantially aligned with adjusting member 624. In an alternateembodiment, adjusting member 624 can disposed so that the head 626 ofadjusting member 624 abuts isolator rail 602. Head 626 can be configuredto engage aperture 612 in isolator rail 602 to function in substantiallyas discussed above. In other alternate embodiments, the head 626 can beaffixed to either the isolator rail 602 or the spring rail 603.

For vibration isolator 600 to function as intended, spring 618 of eachspring isolator 600 must be adjusted to substantially evenly carry thecollective weight of the assembly to be vibrationally isolated andsupporting spring rails. The spring adjustment is achieved by actuatingadjusting member 624 with respect to threaded spring retainer 620 suchthat head 626 of adjusting member 624 moves vertically in a directionaway from threaded spring retainer 620. As head 626 of adjustment bolt624 moves vertically, it abuts spring rail 603. Further actuation ofadjusting member 624 with respect to threaded spring retainer 620, ineffect, compresses spring 618, the spring 618 compressive force bearingthe weight of the assembly to be vibrationally isolated. Although theweight of the vibrationally isolated assembly is supported once thespring isolators 600 have been sufficiently adjusted, vibrationallyisolated lateral support must also be provided for stability and toprevent the centrally positioned protrusion 608 of spring retainer 606from possibly “bouncing out” of engagement with aperture 612 in isolatorrail 602.

To provide this lateral support, a leg of an angle 634 or otherstructural member is secured by a number of corresponding fasteners,such as nuts 646 and bolts 644, to vertical side wall 604 of isolatorrail 602, the horizontally extended leg 636 of angle 634 furthersecuring a grommet 638 therein. A guide member 640, such as a bolt, isthen preferably passed through two axially aligned apertures 642 formedin a pair of flanges 650 of end rail 605 and grommet 638 and secured inposition by a nut 644. Guide member 640 and adjusting member 624 aresubstantially parallel and not coaxial. In this embodiment, spring rail603 defines a C-shaped channel. Grommet 638 provides vibration isolationbetween guide member 640 and angle 634 while guide member 640simultaneously provides the required lateral support for thevibrationally isolated assembly. Furthermore, since the horizontalextending leg 636 is disposed between the two axially aligned apertures642 of the spring rail 603, the total vertical travel of the spring rail603 is limited to the distance between opposed inside surfaces 648 offlanges 650 of the spring rail 603 minus the sum of the thickness of thehorizontally extending leg 636 (“T1”) and the compressed thicknesses ofthe grommet 638 (“T2”) extending from the opposed surfaces of thehorizontal extending leg 636. By selectively controlling the length of avertical leg 637 of angle 634 for a given configuration of rails 602,603, horizontally extending leg 636 can be selectively verticallypositioned between flanges 650 to prevent the centrally positionedprotrusion 608 of spring retainer 606 from possibly “bouncing out” ofengagement with aperture 612 in isolator rail 602. In addition, sinceguide member 640 is structurally carried at two positions by spring rail603 and the horizontally extending leg 638 which provides lateralloading to the spring rail 603 is disposed between these two positions,guide member 640 is not subjected to a cantilevered lateral load. Thisarrangement permits the guide member 640 and spring rail 603 to bereduced in size, i.e., diameter and gauge thickness, respectively,saving material costs and reducing weight, while providing the requiredstructural strength.

During transport of the assembly to be vibrationally isolated, it ispreferable that temporary fasteners 652 (FIG. 23) are used to secure therails 602, 603 to each other until the assembly is assembled at itsfinal destination.

While the invention has been described with reference to a preferredembodiment, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiment disclosed as the best modecontemplated for carrying out this invention, but that the inventionwill include all embodiments falling within the scope of the appendedclaims.

1. A support system for an air handling unit comprising: a first framemember, the first frame member supporting a component of an air handlingunit; a second frame member, the second frame member supporting thefirst frame member; a vibration isolator disposed between the firstframe member and the second frame member, the vibration isolator tosubstantially vibrationally isolate the component of the air handlingunit from the second frame member, the vibration isolator comprising: aresilient device having opposed ends; a first retainer abutting thesecond frame member, the first retainer being configured to receive oneend of the resilient device; a second retainer, the second retainerbeing configured to receive the other end of the resilient device, thesecond retainer being disposed adjacent the first frame member; atensioning member adjustably connected to the second retainer along afirst axis, the tensioning member being disposed to abut the first framemember to support the weight of the first frame member and the componentof the air handling unit and to compress the resilient device betweenthe first retainer and the second retainer; and a stabilization systemto constrain relative movement between the first retainer and the secondretainer comprising: a guide member, the guide member structurallycarried by the first frame member along a second axis by at least twopositions, the second axis being substantially parallel to the firstaxis and not coaxial with the first axis; and a structural member havinga first end and a second end, the first end of the structural membersecured to the second frame member and the second end of the structuralmember slidably engaging the guide member between the at least twopositions of the first frame member; and wherein the second end of thestructural member substantially constraining movement of the componentof the air handling unit along the second axis between the at least twopositions of the first frame member.
 2. The support system of claim 1wherein the component of the air handling unit having vibrating meanscontained therein.
 3. The support system of claim 1 wherein the firstframe member and the second frame member are secured together tocollectively transport the first frame member, the second frame memberand the component of the air handling unit.
 4. The support system ofclaim 1 wherein the resilient device is a spring.
 5. The support systemof claim 1 wherein the resilient device is an air cylinder.
 6. Thesupport system of claim 1 wherein the first retainer is of unitaryconstruction.
 7. The support system of claim 1 wherein the firstretainer has a cupped end.
 8. The support system of claim 7 wherein thefirst retainer comprises a protrusion opposite the cupped end that isreceived by the second frame member.
 9. The support system of claim 8wherein the protrusion is substantially aligned with the first axis. 10.The support system of claim 1 wherein the second retainer is of unitaryconstruction.
 11. The support system of claim 1 wherein the secondretainer has a cupped end.
 12. The support system of claim 1 wherein thefirst end of the tensioning member has a plurality of flats formedthereon.
 13. The support system of claim 12 wherein at least two of theplurality of flats are parallel.
 14. The support system of claim 13wherein the plurality of flats forms a hexagon.
 15. The support systemof claim 14 wherein the first end of the tensioning member threadedlyreceives a fastener having a head, the fastener directed substantiallyparallel to the first axis, the fastener directed through an apertureformed in the first frame member when the fastener threadedly engagesthe first end, wherein sufficiently rotating the fastener head about thefirst axis with respect to the tensioning member in a direction thatactuates the fastener head toward the head of the tensioning memberuntil the head of the fastener compresses a portion of the first framemember adjacent the aperture between the fastener head and the first endof the tensioning member to prevent the tensioning member from rotatingabout the first axis.
 16. The support system of claim 1 wherein thestructural member is an angle member.
 17. The support system of claim 1wherein the first frame member defines a C-shaped channel having a pairof substantially parallel flanges.
 18. The support system of claim 17wherein the second end of the structural member is slidably engagedbetween the pair of flanges.
 19. The support system of claim 18 whereinthe second end of the structural member comprises a grommet to slidablyengage the guide member.
 20. A support system for an air handling unithaving a first compartment supported atop a second compartmentcomprising: a first frame member, the first frame member supporting thefirst compartment; a second frame member, the second frame membersupporting the first frame member, the second frame member disposed atopthe second compartment; a vibration isolator disposed between the firstframe member and the second frame member, the vibration isolator tosubstantially vibrationally isolate the first compartment from thesecond frame member, the vibration isolator comprising: a resilientdevice having opposed ends; a first retainer abutting the second framemember, the first retainer being configured to receive one end of theresilient device; a second retainer, the second retainer beingconfigured to receive the other end of the resilient device, the secondretainer being disposed adjacent the first frame member; a tensioningmember adjustably connected to the second retainer along a first axis,the tensioning member being disposed to abut the first frame member tosupport the weight of the first frame member and the first compartmentto compress the resilient device between the first retainer and thesecond retainer; and a stabilization system to constrain relativemovement between the first retainer and the second retainer comprising:a guide member, the guide member structurally carried by the first framemember along a second axis by at least two positions, the second axisbeing substantially parallel to the first axis and not coaxial with thefirst axis; a structural member having a first end and a second end, thefirst end of the structural member secured to the second frame memberand the second end of the structural member slidably engaging the guidemember between the at least two positions of the first frame member; andwherein the second end of the structural member substantiallyconstraining movement of the first compartment along the second axisbetween the at least two positions of the first frame member.
 21. Thesupport system of claim 20 wherein the air handling unit has a pluralityof frame members, the plurality of frame members supporting the firstframe member, the plurality of frame members disposed atop the secondcompartment.